Apparatus for the extrusion of plastic net and net like structures

ABSTRACT

An improved extrusion apparatus and method for the extrusion of plastic net and net-like structures is provided. The apparatus is comprised of a plurality of die members at least one of which reciprocates in a vertical direction. One of the die members has a plurality of orifices therein for the extrusion of a first group of strands and at least one other die member has a forming surface thereon which coacts with a second forming surface on another die member to form a variable opening for the independent extrusion of a second group of strands. The distance between each orifice is maintained constant and the second group of strands is extruded at a point below that at which the orifices communicate with a polymer supply. The forming surfaces and orifices are so arranged relative to each other that at least one group of strands is forcefully urged toward the other group to cause the two groups of strands to weld together subsequent to extrusion.

United States Patent 1191 Gaffney Oct. 23, 1973 I 1 APPARATUS FOR THE EXTRUSION OF PLASTIC NET AND NET LIKE STRUCTURES [75] Inventor: Bernard J. Gaffney, Stillwater,

[21] Appl. No.: 250,490

Related U.S. Application Data [62] Division of Ser. No. 875,476, Nov. 10, 1969, Pat. No.

[52] U.S. Cl 425/464, 425/131, 425/466, 264/DIG. 81, 156/500 [51] Int. Cl B29f 3/04 [58] Field of Search 264/167, DIG. 81,

264/103, 167; 16l/DIG. 6; 156/500, 167, 441,181,180, 244, 242; 425/382,l3l, 133,

[56] References Cited UNITED STATES PATENTS 3,349,434 10/1967 Hureau 425/464 3,444,588 5/1969 Martin et al. 3,123,512 3/1964 M61661 3,172,154 3/1965 Martin et al. 3,331,903 7/1967 Sigeta 425/463 x Fr 3,358,329 12/1967 Martin et a1. 425/464 FOREIGN PATENTS OR APPLICATIONS 1,310,478 l/1963 France 264/DIG. 81 46,932 3/1960 Poland 264/DIG. 81

Primary ExaminerJ. Spencer Overholser Assistant ExaminerMichael 0. Sutton Att0rney-Eyre et al.

[57] ABSTRACT An improved extrusion apparatus and method for the extrusion of plastic net and net-like structures is provided. The apparatus is comprised of a plurality of die members at least one of which reciprocates in a vertical direction. One of the die members has a plurality of orifices therein for the extrusion of a first group of strands and at least one other die member has a forming surface thereon which coacts with a second forming surface on another die member to form a variable opening for the independent extrusion of a second group of strands. The distance between each orifice is maintained constant and the second group of strands is extruded at a point below that at which the orifices communicate with a polymer supply. The forming surfaces and orifices are so arranged relative to each other that at least one group of strands is forcefully urged toward the other group to cause the two groups of strands to weld together subsequent to extrusion.

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APPARATUS FOR THE EXTRUSION F PLASTIC NET AND NET LIKE STRUCTURES This is a division of application Ser. No. 875,476, filed Nov. 10, 1969, and now US. Pat. 3,700,521.

The extrusion apparatus of the present invention is comprised of a plurality of die members for the extrusion of molten polymer to form plastic net and net like products. At least one of the die members has a plurality of orifices therein with a set predetermined opening, for the extrusion of a first group of strands. A second die member has a forming surface thereon parallel to a similar surface on the first or on another die member with which it coacts to form a restricted polymer flow path for the separate extrusion of a second group of strands substantially normal to the first group when the surfaces are separated to permit polymer to flow therebetween. A constant distance is maintained between each orifice and the orifices and the opening between the forming sufaces are not connected whereby the first group of strands and the second group of strands are separately extruded. This separation between the orifices and opening of the forming surfaces permits the forming surfaces to be opened to extrude the second group of strands without stopping or significantly slowing the rate of extrusion of the first group of strands as may occur where only a single variable orifice is provided for the integral extrusion of both the first and second group of strands. In most instances, the first group of strands are extruded as a plurality of parallel longidutinal strands and the second group is extruded as a succession of single strands positioned transverse to the longidutinal strands.

The die members may be arranged in a line for the extrusion of'a flat net or the die members can be in a circular arrangement for the extrusion of a tubular net.

Polymer such as polypropylene is fed to the orifices which may have any cross sectional shape and the opening between the forming surfaces from either a single pressurized pool of molten polymer or from separate pressurized pools which force the molten polymer to extrude. To achieve a high strength bond between the two groups of strands, the arrangement of the orifices and the forming surfaces must be such as to direct one group of strands toward the other to cause bonding at the point where contact occurs. The forming surfaces help to shape the strand as the polymer-flows therebetween and these surfaces materially assist in controlling the velocity and direction of explusion' of the strand. inmost cases, the best bond is achieved by extruding the longitudinal strands in a vertical direction with the transverse strand extruded from between the forming surfaces which are positioned at an angle to the longitudinal strands. in this way, the transverse strand is directed toward the longitudinal strands and, due to the pressure behind the transverse strand, there is a tendency for some intermixing of the polymer of both strands to give a welded bond rather than a mere tack on type of bond in which only the surface layers of the strands are in contact. The length of the forming surfaces is preferably at least equal to the thickness of the strand so that upon closing, the forming surfaces will squeeze the polymer flowing therebetween to increase the explusion velocity of the polymer and its tendericy to intermix with the longitudinal strands.

When an open pore net is to be manufactured by the dies of the present invention, the die member must be reciprocated to open the forming surfaces at predetermined intervals. The die member must be reciprocated between a first position in which the forming surfaces are in contact with each other and a second position in which the forming surfaces are separated by a predetermined distance approximately equal to the desired thickness of the extruded transverse strand. The size of the transverse strand is determined by the distance between the separated forming surfaces, the amount of time that the forming surfaces remain separated and by the magnitude of the pressure used to force the polymer to extrude. However, the extruded thickness of the transverse strand is generally somewhat greater than the distance between the separated forming surfaces due to expansion of the polymer as it is extruded. It is within the skill of the art to determine the relationship between the variables and the exact distance needed between forming surfaces to achieve a desired extruded strand size and thickness. The length of the extruded transverse strand is determined by the length 'of time the forming surfaces are separated. Reciprocation or cyclic movement of one of the die members and the feeding of the hot plastic under pressure to the die members of the present invention for extrusion of plastic products is carried out in conventional manner well known in the art. For example, one method and apparatus for automatically controlling the movement of the die members to extrude plastic net and other products is described in a commonly assigned, copending application Ser. No. 877,686 filed Nov. 18, 1969. The orifices for extruding the longitudinal strands may be positioned in the moveable or stationary die member or in both of the die members and any number of die members may be employed. If desired, a group of longitudinal strands may be extruded on both sides of the transverse strands simply by providing a plurality of orifices in both die members and the orifices may be angled to direct the longitudinal strands against the extruded transverse strand.

In all cases, separate longitudinal and transverse extrusion orifices are used so that the extrusion of each strand is carried out independently and the transverse strand is discharged from between the forming surfaces below the point atwhich the longitudinal strand extrusion orifices communicate with the pressurized pool of polymer.

If desired, the orifice openings for the longitudinal strands may be reduced in size as the forming surfaces open in order to balance thetotal polymer flow between the longitudinal orifices and the transverse opening to bring the thickness of the netat the point of cross over of the strands down to the thickness 'of one individual strand. A conventional baffle timed to restrict or completely close. the opening of the longitudinal strand orifices may be employed for this purpose.

The dies of the instant invention may also be used to extrude a solid sheet with longitudinal ribs by permitting the forming surfaces to always remain open.

Referring now to the drawings in which are depicted various embodiments of the preferred instant invention and in which like numerals refer to like parts:

FIG. 1 is a sectional view of one form of die embodying the principles of this invention;

FIG. 2 is a sectional view of another form of die.

I FIG. 3 is a sectional view of still another form of die.

FIG. 4 is a sectional view of still another form of die embodying the principles of this invention and in which the orifices for the extrusion of the longitudinal strands movein a vertical direction.

FIG. 5 is a bottom view taken along line 5-5 of FIG. 4.

FIG. 6 is an enlarged detail view of the extrusion orifice and forming surfaces taken along line 6-6 of FIG. 6.

FIG. 7 is a cross sectional plan view of a product produced by the dies of FIG. 4.

FIG. 8 is a cross sectional plan view of still another form of die embodying the principles of this invention.

Referring now to FIG. 1, the die assembly 10 has an inner moveable round die member 11 that is reciprocated in vertical direction in conventional manner and an outer stationary round die member 12. Die member 12 has an annular cavity 13 therein to which molten polymer is supplied under pressure by conventional means such as a screw extruder (not shown).

Die member 12 has a plurality of holes 14 bored therein (two only shown) which are in fluid communication with the polymer of cavity 13 and with the orifice opening 15. Longitudinal strands 16 are continuously extruded through holes 14 and orifices 15. In the embodiment shown, orifices are arranged in a circle to extrude the plurality of longitudinal strands in a circle. However, the orifices 15 may be arranged in a rectangular or other square pattern to extrude the strands in other than a circular arrangement.

The annular cavity 13 is also in fluid communication with an annular surface 19 on die member 12 and with an annular forming surface 20 on die member 11. Die member 11 is mounted on a reciprocating shaft 21 which causes the member to move up and down in vertical direction. In the position shown in FIG. 1, the forming surfaces 19, 20 are closed and no polymer can flow between the surfaces. Upon movement of shaft 21 downwardly, the forming surfaces 19, 20 separate whereupon polymer from cavity 17 flows under pressure in between the two forming surfaces and, as the surfaces close, the polymer is squeezed out to complete the formation of a transverse strand 22.

Forming surfaces 19, 20 are positioned perpendicular to the direction of extrusion of longitudinal strands l6 and as a result, the transverse strand is directed to move into the longitudinal strand to form a welded bond between the strands. The length of forming surfaces 19, 20 is equal to the thickness of the transverse strand and with this construction, the strand is shaped between the forming surfaces and then expelled against the longitudinal strands by the squeezing action of the forming surfaces as they close to cut off the polymer.

The orifices 15 are set a predetermined distance apart and they are separated from the forming surfaces so that the longitudinal and transverse strands are extruded independently of each other. The strands are joined together at a point below that place where the orifice is connected to cavity 13 so that the longitudinal strand is completely formed before the two are joined together. By extruding the transverse and longitudinal strands separately, the extrusion of one has little influence on the extrusion of the other and the extrusion variables, as for instance pressure within the orifices which in part defines the shape of the longitudinal strands, will not be materially affected by the opening of the forming surfaces for extrusion of the transverse strands.

The FIG. 2 embodiment of the die is essentially the same as the FIG. 1 embodiment. The only difference between them is that the annular forming surfaces 19, 20 in the die of FIG. 2 are of somewhat greater length than shown in FIG. 1 and the forming surfaces are slanted downwardly towards longitudinal strands l6. Slanting the forming surfaces downwardly i.e. placing them at a positive angle less than from the horizontal as depicted in the drawing wherein 23 denotes the horizontal and arrow 24 denotes the direction in which the positive angle is to be measured, isof advantage in that as the forming surfaces close to cut off polymer flow, an added force component is imposed on the flowing polymer in the direction of extrusion which is the resultant of the force used to close the die members. The added force component enhances the squeezing effect and it tends to increase the bond strength between the longitudinal and transverse strands.

In the embodiments of both FIGS. 1 and 2, the high pressure used to extrude the polymer into strands will often force the polymer into any clearance space such as 25 between the die members 11 and 12. Polymer in the clearance space 25 will subsequently work its way up along the surface of the shaft 21 where the polymer is kept hot due to the heat of the shaft. The polymer will eventually degrade and cause gumming and sticking of the shaft. Normally, periodic removal and cleaning of the shaft is necessary. To avoid this problem, a plurality of weep holes 26 are provided in communication with space 25. Weep holes 26 have a large diameter opening whereby polymer will flow more easily into the weep holes and out to the atmosphere rather than up along the shaft. If desired, the die member 12 may be reciprocated instead of die member 11 or both may be reciprocated in opposite directions by conventional means. In addition to the above, the forming surfaces may be placed outside the longitudinal orifices to extrude horizontal strands inwardly against the longitudinal strands instead of outwardly as shown.

Referring to FIG. 3, another form of die is shown in which the inner die 11 is extended upwardly above the point at which extrusion holes 14 connect with cavity 13. Inner die 11 has an inwardly extending annular flange 27 on which a plurality of half sphere plugs 28 are mounted by conventional means. One plug 28 is provided for each one of the holes 14 which are dished at 29 to decrease the flow of polymer from orifices 15. In addition, a plurality of orifices 29a are spaced around the circumference of flange 27 to permit polymer to flow to the forming surfaces 19 without encountering the obstruction imposed on flow by plugs 28. In this manner, the flow of polymer may be balanced to decrease the thickness of the joint formed between the strands.

Referring now to FIGS. 4 through 6, there is seen another die embodying the principles of this invention. In this embodiment, the stationary outer die member 12 has its annular forming surface 19 extended inwardly approximately half way across orifice 15 as seen at 30 in FIG. 5. The portion of the forming surface 19 which extends into orifice 15 is drilled or cut back at 31 so as not to interfere with the continuous extrusion of the longitudinal strands 16. Die member 11 in this embodiment is a vertically reciprocating collar which has an opening 33 therein for accepting shaft 21 which is conventionally keyed to the die member 11 (not shown). Die member 11 has an annular flange 34 in which the orifices are located, along with the annular forming surface 20.

In operation, the longitudinal strands 16 are continuously extruded from the annular cavity 13. When die member 1 l is moved upwardly from the position shown in FIGS. 4 and 6, the annular forming surfaces 19, separate to permit the transverse strand 22 to extrude into the longitudinal strands l6. Upward movement of the orifices 15 will tend to momentarily reduce the flow of plastic to thin out the longitudinal strand 16.at the point of contact with the transverse strand 22. Thisdecreases the joint thickness and gives a more pleasing appearance to the net structure. Extension of forming surface 19 forces portions of the transverse strand into the space between the longitudinal strands l6 and this assists in the intermixing of polymer of the longitudinal and transverse strands beyond that obtained with the other forms of die members because each longitudinal strand is partially encapsulated by the transverse strand as shown in the drawing of FIG. 7. This partial encapsulation tends toincrease the strength of the bond between the polymer strands.

Although encapsulation is desired, it is not necessary and extension 30 on the forming surface 19 may be removed by cutting it back to point 31 if this is desired.

Referring now to FIG. 8, the outer die member 12 has only two separate annular groups of orifices l5 and 15a respectively for the extrusion of two separate groups of longitudinal strands. Die member 12 has two forming surfaces 19 and 19a which coact with two forming surfaces 20 and 20a on the moveable die member 11. Forming surfaces 19 and 20 are positioned in between the groups of orifices l5 and 15a and the forming surfaces 20 converge to form an extension on the inner die at which projects down below the orifices l5 and 15a to separate the two groups of longitudinal strands. Holes 14 that connect orifices l5 and 15a with the .annular cavity 13 are angled towards each other and the two groups of longitudinal strands which are continuously extruded are'kept separated by the extension 35 of the inner die member 11. In the position shown in the drawing the forming surfaces 19 and 20 are in contact and no polymer can flow between the surfaces. Upon upward movement of die member 11 the forming surfaces 19, 20 separate-to extrude two separate polymer strands that join together to form a single transverse strands 22 below the tip of extension 35 which is now in the retracted position. Due to the retracted position of extension 35, the two groups of longitudinal strands are forcefully urged into thetransverse strand 22 to form a strong, welded bond therebetween.

In all of the embodiments described above, the forming surfaces may be maintained permanently separate for the extrusion of a continuous sheet of polymer and in such case the longitudinal strands from the orifices will form reinforcing ribs on the sheet. The inner and outer die may be reciprocated and more than two die members may be used to form the desired number of strands. Additionally, more than one group of orifices and moveable surfaces may be positioned in each die member, for the extrusion of a greater number of groups of strands than there are die members as in the structure of FIG. 8.

In all of the embodiments in which a tubular product is extruded, it is preferred to extrude the product over a mandrel or some other device (not shown) having somewhat larger dimensions than the product in order to place the longitudinal and transverse strands of the product under tension to promote better bonding between the two strands. If desired, the mandrel used may have an inner opening in the form of a nozzle (not shown) through which the extruding net is directed and expanded as it leaves the nozzle'by nip rolls (conventional) or other means to place the strands of the net under tension by the restriction imposed on movement of the net by the nozzle.

It is intended to cover all changes and modifications of the preferred embodiments of the invention herein chosen for the purpose of illustration which do not constitute departures from the spirit and scope of the invention.

What is claimed is:

1. A die for the extrusion of aflowable polymer which comprises at least two die members, means for moving one of said die members in vertical direction, at least one forming surface on each of said die members, said forming surfaces being in position to coact to open and close upon vertical movement of one of the said die members for the extrusion of polymer when said forming surfaces are open, a plurality of orifices with a set predetermined opening in at least one of said die members, said orifices being separated from said forming surfaces of the continuous independent extrusion of a plurality of separate longitudinal strands of polymer, means for supplying polymer to said orifices and forming surfaces, said forming surfaces and orifices being positioned in said die members to direct the extruded polymer therefrom to join together and bond into a unitary structure subsequent to extrusion and in which there are only two said die members, each of said die members having a plurality of orifices, the orifices in one die member being angled towards the orificesof the other die member to extrude two sets of said strands towards each other, said die members having two flowing surfaces thereon, the forming-surfaces of each die member being positioned in between the orifices of the die members, the forming surfaces on each die member'being convergent towards each other in the direction of extrusion with the forming surfaces of one die membermeeting at a predetermined point to form an extension which projects down below said orifices to keep said two first .groups from contacting each other when the forming surfaces of the die members are closed to polymer flow whereby when said die members are vertically moved to move said forming surfaces apart to permit polymer to flow therebetween, said juncture is moved to permit the two sets of strands to flow against the polymer being extruded from between the forming surfaces.

2. An extrusion apparatus as specified in claim 1 wherein the forming surfaces on one of said die members has an extension thereon, said extension projecting across said orifices and being cut back in the area of said orifices to permit the unobstructed extrusion of said strands, said extension forcing polymer flowing between the forming surfaces to flow against and between said first group of strands.

3. A die for the extrusion of a flowable polymer which comprises at least two die members, means for moving one of said die members in vertical direction, at least one forming surface on each of said die members, said forming surfaces being in position to coact to open and close upon vertical movement of one of the said die members for the extrusion of polymer when said forming surfaces are open, a plurality of orifices with a set predetermined opening in at least one of said die members, said orifices being separated from said forming surfaces for the continuous independent extrusion of a plurality of separate longitudinal strands of polymer, means for supplying polymer to said orifices and forming surfaces, said forming surfaces and orifices being positioned in said die members to direct the extruded polymer therefrom to join together and bond into a unitary structure subsequent to extrusion and wherein one of said die members has an extension flange thereon positioned above the point at which the orifices of the other die member communicate with the molten polymer, said flange having a plurality of baffle means thereon adapted to cooperate with said orifices in the other die member whereby when said die members are moved relative to each other, the baffle means move toward and away from said orifices in the other die member to control the flow of polymer therethrough.

4. Apparatus for melt extrusion of a solidifiable thermoplastic polymer tube comprising:

a. means for melt extruding a plurality of polymer strands in the direction of extrusion;

b. separate means for intermittently melt extruding a succession of separate polymer pieces, said polymer pieces being extruded in a direction normal to the direction of extrusion and said separate means being disposed to extrude said polymer pieces separate from the extruded plurality of polymer strands; and

c. means for joining the separate polymer'pieces to at least two of the plurality of polymer strands, said means for joining being disposed to effect joining after the plurality of polymer strands and the separate polymer pieces have been separately extruded and while they are still molten whereby the separate polymer pieces and the plurality of polymer strands join together and bond into a unitary structure subsequent to the separate extrusion of the polymer pieces and the plurality of polymer strands.

5. The apparatus of claim 4 wherein there are means for extruding two pluralities of polymer strands, one inside and one outside the means for extruding the separate polymer pieces.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,767,353 Dated October 23, 1973 PRINTERS TRIM L Inventor(s) Bernard J. Gaffney It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Col. Line 27 (Claim 1) "surfaces of the continuous" should read --surfaces for the continuous-- Signed and sealed this 9th day of April 19714..

(SEAL) Attest:

EDWARD M.FLETCHER,JR. o. MARSHALL DANN Atte sting Officer Commissioner of Patents FORM PO-1050 (10-69) USCOMM-DC 60376-P69 fir u.s. GOVERNMENT PRINTING OFFICE: 1969 0366-3l4 

1. A die for the extrusion of a flowable polymer which compriseS at least two die members, means for moving one of said die members in vertical direction, at least one forming surface on each of said die members, said forming surfaces being in position to coact to open and close upon vertical movement of one of the said die members for the extrusion of polymer when said forming surfaces are open, a plurality of orifices with a set predetermined opening in at least one of said die members, said orifices being separated from said forming surfaces for the continuous independent extrusion of a plurality of separate longitudinal strands of polymer, means for supplying polymer to said orifices and forming surfaces, said forming surfaces and orifices being positioned in said die members to direct the extruded polymer therefrom to join together and bond into a unitary structure subsequent to extrusion and in which there are only two said die members, each of said die members having a plurality of orifices, the orifices in one die member being angled towards the orifices of the other die member to extrude two sets of said strands towards each other, said die members having two flowing surfaces thereon, the forming surfaces of each die member being positioned in between the orifices of the die members, the forming surfaces on each die member being convergent towards each other in the direction of extrusion with the forming surfaces of one die member meeting at a predetermined point to form an extension which projects down below said orifices to keep said two first groups from contacting each other when the forming surfaces of the die members are closed to polymer flow whereby when said die members are vertically moved to move said forming surfaces apart to permit polymer to flow therebetween, said juncture is moved to permit the two sets of strands to flow against the polymer being extruded from between the forming surfaces.
 2. An extrusion apparatus as specified in claim 1 wherein the forming surfaces on one of said die members has an extension thereon, said extension projecting across said orifices and being cut back in the area of said orifices to permit the unobstructed extrusion of said strands, said extension forcing polymer flowing between the forming surfaces to flow against and between said first group of strands.
 3. A die for the extrusion of a flowable polymer which comprises at least two die members, means for moving one of said die members in vertical direction, at least one forming surface on each of said die members, said forming surfaces being in position to coact to open and close upon vertical movement of one of the said die members for the extrusion of polymer when said forming surfaces are open, a plurality of orifices with a set predetermined opening in at least one of said die members, said orifices being separated from said forming surfaces for the continuous independent extrusion of a plurality of separate longitudinal strands of polymer, means for supplying polymer to said orifices and forming surfaces, said forming surfaces and orifices being positioned in said die members to direct the extruded polymer therefrom to join together and bond into a unitary structure subsequent to extrusion and wherein one of said die members has an extension flange thereon positioned above the point at which the orifices of the other die member communicate with the molten polymer, said flange having a plurality of baffle means thereon adapted to cooperate with said orifices in the other die member whereby when said die members are moved relative to each other, the baffle means move toward and away from said orifices in the other die member to control the flow of polymer therethrough.
 4. Apparatus for melt extrusion of a solidifiable thermoplastic polymer tube comprising: a. means for melt extruding a plurality of polymer strands in the direction of extrusion; b. separate means for intermittently melt extruding a succession of separate polymer pieces, said polymer pieces being extruded in a direction normal to the directioN of extrusion and said separate means being disposed to extrude said polymer pieces separate from the extruded plurality of polymer strands; and c. means for joining the separate polymer pieces to at least two of the plurality of polymer strands, said means for joining being disposed to effect joining after the plurality of polymer strands and the separate polymer pieces have been separately extruded and while they are still molten whereby the separate polymer pieces and the plurality of polymer strands join together and bond into a unitary structure subsequent to the separate extrusion of the polymer pieces and the plurality of polymer strands.
 5. The apparatus of claim 4 wherein there are means for extruding two pluralities of polymer strands, one inside and one outside the means for extruding the separate polymer pieces. 